PROJECT SUMMARY
In 1998, the U.S. Department of Homeland Security (DHS) (the former Immigration and Naturalization Service) was under a Government mandate to reduce the increasingly growing backlog in the production of alien registration cards. The Integrated Card Production System (ICPS) equipment was not performing well in existing/renovated spaces. The card production throughput is very sensitive to the environment that houses the ICPS equipment. Fluctuation in temperature and humidity, power surges as well as airborne dust particulates must be controlled. Additionally, the card production must be in a secured facility.

DHS was scheduled to take possession of three of the latest generation ICPS equipment but had no adequate facilities to install and effectively test, accept and operate the sensitive equipment. Based on lessons learned on previous ICPS renovated facilities, DHS decided to build a new facility rather than renovate and use existing space. The challenge was to select a project site, design and construct a brand new technically demanding $5.2 million 24,000 SF facility that would be operational within seven months. The team successfully met these objectives and built the state-of-the-art Corbin Card Production Facility (CPF) in South Eastern Kentucky within the stated project schedule and budget. In addition to time constraints, this facility had to be completed within the government procurement process as established by Legacy INS and GSA. The challenge also included designing a new program to accommodate facility operations. As Legacy INS had no facility similar to the Card Production Facility anywhere, new program functions had to be created.

In order to meet the stated project goals, the project was run on a "super-fast-track" schedule. HDR working with the INS Project Architect completed the design in less that two months and the contractor built the entire facility in only 120 days. This was accomplished through a true partnership of private companies and government agencies working within the framework of the Federal procurement system for a build-to-suit/leaseback arrangement with out-of-the-box thinking. While the CPF was not a "true" design-build delivery method, the DHS, GSA, HDR and HCOK team had to continuously collaborate and everyone contributed to the success of the project in an accelerated manner.

The Corbin Card Production Facility was designed around the sophisticated card production process. To properly operate, the equipment required a high level of environmental control in the facility. Some of the design features for this project included:

• Environment
• Temperature Control
• Humidity Control
• Cleanroom" environment in four 30ft x 75ft structural bays
• Day lighting in ICPS rooms
• Electrical Engineering
• Clean Power (dedicated circuits with isolated ground)
• UPS (equipment backup and orderly shutdown)
• Generator Back Up (continuous operation, life safety and security)
• Security
• Physical Security (barriers, forced entry protection, etc.)
• Electronic Security (access control, CCTV, etc.)

The Card Production Facility was successfully completed in the fall of 1998 and continues to provide the DHS with the right infrastructure to maintain timely production of alien registration cards. Despite the high tech nature of the facility, all of the building aspects were triumphantly fulfilled with respect to the fast track construction schedule. Using an unconventional approach via architect partnering with the developer/contractor, a state-of-the-art card production facility was designed, built and operational within record time. Through a collaborated effort between DHS, GSA, HDR and the Contractor, the project requirements were fulfilled within the schedule and budget requirements.